NAVISTAR MPAPS P-9555-2014 Quality Requirements For Fuel Tanks.pdf

1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 1 of 11 NAVISTAR, INC. Material, Parts, and Process Specifications

2、(MPAPS) NUMBER: MPAPS P-9555 Former Designation: TMS-9555 TITLE Quality Requirements For Fuel Tanks CURRENT REV. No: 1406 DATE: JUNE 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-9555 - OCT. 2013 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR

3、CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicabili

4、ty of regulatory limits prior to use. Change Notice: Changed to new MPAPS format; revised Section 4.2.2.2 for compression fittings; editorial changes. 1.0 APPLICATION This specification covers Engineering quality requirements for purchased fuel tanks used on Navistar trucks as assembled in Navistar

5、plants, and to such components as may be provided for field service applications. 2.0 SCOPE Metal fuel tanks consist of a center section with end-caps, fill-pipe, and flanges or spuds suitable for the installation of all fittings. The center section, end-caps, fill-pipe, and flanges are all suitably

6、 welded to provide a single unit for assembly or service. The plastic fuel tank consists of a plastic shell, fill-pipe, and flanges or spuds suitable for the installation of all fittings. The plastic shell, fill-pipe, flanges and inserts are all suitably molded to provide a single unit for assembly

7、or service. This specification covers the material and performance requirements of aluminized steel, aluminum, and plastic fuel tanks, including requirements of the Process Verification Plan and Report, the manufacturing quality plan, quality control and source approval, suppliers compliance reports

8、, painting, appearance criteria, and shipping and identification requirements. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unles

9、s otherwise specified, the latest issue of all referenced standards shall apply. The following specifications, standards, and regulations are referenced in this specification: Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS A-6, Part I FMCSR 393.65 CFR Title 23, Part 658 NAVISTAR MPAPS A

10、-6, Part II FMCSR 393.67 CFR Title 29, Part 1910 NAVISTAR MPAPS B-32 Alum. Assn AA 45 NAVISTAR Manufacturing Std MS-D-13 NAVISTAR MPAPS C-10 TMS-9009 NAVISTAR RQ-COM-0032-WI NAVISTAR TMS-4513 TMS-9605 NAVISTAR TEM-PR-7.03 ASME Y14.5M-1994* NAVISTAR TMS-9511 NAVISTAR TMS-9512 CEMS G-7 MPAPS K-6929 NA

11、VISTAR MPAPS B-50 NAVISTAR MPAPS P-9543 EPS-145 AWS D1.2, D1.1, D1.3 MPAPS D-28 SAE J703 ASTM D 1435 ECE 34 annex 5 NBR 11477 *Conformance to the 1994 version of ASME Y14.5M is required. NUMBER: MPAPS P-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 1406 This document is restricted and ma

12、y not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 2 of 11 4.0 GENERAL REQUIREMENTS 4.1 Design Guidelines 4.1.1 GD at test conclusion, no failure of mou

13、nting hardware or more than 1 mm of wear into the tank surface is allowed. 4.3.2.3.7 Slosh Test Plastic-specific fuel tank will pass a slosh test with the following conditions: Fill volume: 25%, 50% on the BTR tanks the label shall be on the tank bottom which must be clearly visible. Welded labels a

14、re not acceptable. New metallic fuel tank labels shall be etched or engraved per CEMS G-7 PSF-8CY8. Service labels shall be made of adhesive backed anodized aluminum. The adhesive shall be acrylic foam a minimum of 0.5 mm thick and shall meet the requirements of CEMS G-7 PSF-8CY8 and MPAPS K-6929. S

15、ee MPAPS K-6929 Part 2 for Design Guidelines, Process Considerations, and Validation. Alternately, the information may be etched, engraved, embossed, or molded directly to the tank with prior engineering approval. See Engineering Procedural Standard EPS-145 for guidelines on the color and compositio

16、n of graphics. Prior to production, proposed layout of product graphic shall be approved by Navistar Corporate Technical Standards Department and Industrial Design. 4.4.1 Compliance Documentation Supplier shall submit documentation reporting results of all compliance testing performed in Section 4.3

17、.2. The reports shall be prepared in accordance with MPAPS P-9543. 4.4.1.1 Recipients Copies of each Compliance Report shall be sent to the following: NUMBER: MPAPS P-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc.

18、 or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 6 of 11 Navistar, Inc. Chassis Engineering - Fuel Systems 2601 Navistar Drive Lisle, IL 60532 Attention: Chief Engineer 4.5 PVP&R Plan A

19、manufacturing process verification plan and report will be developed to insure that the manufacturing processes employed are capable of meeting all requirements of this specification as is described in Section 6.0 of this specification. 5.0 QUALITY All fuel tanks shall be supplied in a clean and dry

20、 condition. For steel tanks which will be painted, the surface cleanliness requirements of Section 5.1 will be met. After painting, the manufacturer will perform oil fogging of the interior surfaces of steel fuel tanks. Open holes will be plugged to prevent moisture entrance or fogging oil leakage.

21、Tanks shall be free of rust at the point of application at the assembly plant. All assembly or test fluids/fuels that may remain or leave a residue in the fuel tank must be compatible with Navistar factory fill fuels and must not have a detrimental effect on the fuels ability to meet all chemical an

22、alysis requirements of the MPAPS B-32 specification. Finished fuel tanks must meet the Surface Appearance Acceptance Criteria as described in Table 1. 5.1 Exterior Surface Cleanliness Requirements 5.1.1 White Glove Test for Metallic Fuel Tanks After cleaning and prior to application of any pretreatm

23、ent and/or paint to the tank, a “white glove test” must be performed. After wiping the tank in locations representing all surface conditions with a suitable white cloth material, there should be no visual evidence of soil or contamination of any kind. 5.1.2 Water Break Free Condition for Metallic Fu

24、el Tanks In addition to the white glove test, there must also exist a “water break free” condition over the entire exterior tank surface. This must be verified by applying an atomized mist of distilled water to the surface of the tank and examining the coverage of the water. If the water droplets co

25、alesce into large lenses lasting for 25 seconds (without sudden flash-out), the surface is considered satisfactorily clean. If the water gathers into droplets within 25 seconds (i.e., a water-break condition exists), the surface will be considered as having failed the test. If the water mist forms a

26、 continuous film by flashing out quickly over a large area, this will be considered evidence of an impurity on the surface (e.g., free alkali, residual detergent, etc.) and the surface shall be considered as having failed the test. If more than 4 hours have passed since performing either the white-g

27、love or water break test, tanks must be re-examined for surface corrosion, dirt, foreign matter, or oily residue and the tests must be repeated. Failure of either of the above two tests mandates that additional cleaning procedures be performed until both tests can be passed. 5.2 Interior Cleanliness

28、 Interior fuel tank surfaces shall be free of weld spatter and shavings from manufacturing processes. The maximum allowable amount of contaminant shall be less than 2.5 grams using a flush and 10 micron filter capture. Interior fuel tank surfaces shall be free of weld spatter and shavings from manuf

29、acturing processes. The maximum allowable amount of contaminant shall be less than 2.5 grams using a flush and 10 micron filter capture. The fuel tank manufacturer shall protect the fuel tank interior by securely sealing all openings to prevent powder, dirt, moisture, corrosive vapors, or sprays fro

30、m entering the fuel tank prior to assembly on the vehicle, unless this requirement is specifically waived by Navistar. The NUMBER: MPAPS P-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permi

31、ssion from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 7 of 11 fuel tank manufacturer shall submit quarterly certification stating that all fuel tanks shipped during each quarter fully comply with this specification. Thi

32、s certification is not meant to state or imply that every fuel tank has been tested, but that manufacturing process controls assure that the desired level of quality can be expected in every fuel tank shipped. In addition, the fuel tank manufacturer shall provide inspection records, test methods, an

33、d results to Navistar personnel upon request. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to Navistar, Inc. are required to be registered to ISO 9001 Quality System Requirements. Navistar will also accept TS-16949 registration as long as the supplier can also fulf

34、ill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Navistar Corporate Buyer upon request. 6.2 Approval Parts supplied agai

35、nst contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practic

36、es, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated

37、 Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide sta

38、tistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using plant may determine testing and reporting requirements on specific products. 7.0 SHIPPIN

39、G, PACKING AND IDENTIFICATION Loading, packing, and identification shall be in accordance with Manufacturing Std. MS-D-13. 8.0 DESIGNATION ON DRAWINGS Type of material to be used for fuel tanks should be specified in the material block of the applicable drawing. Examples: Steel per MPAPS P-9555 Poli

40、shed Aluminum per MPAPS P-9555 Non-polished Aluminum per MPAPS P-9555 Plastic per MPAPS P-9555 Note that painted tanks do not require a TMS-9009 paint stamp on drawings since the paint requirements are covered by this specification. Additional notes in body of drawing should read: “Fuel tanks must m

41、eet performance and quality requirements of MPAPS P-9555.” and “Refer to MPAPS P-9555 for torque requirements.” NUMBER: MPAPS P-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 1406 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from

42、Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 8 of 11 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this spec

43、ification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ 10.0 APPROVED COATING FOR FILLE

44、R NECK INTERIOR Metal Ready (manufactured by POR-15) - Preconditioner to remove rust & prepare tank for sealer. Sealer - U.S Standard Fuel Tank Sealer (manufactured by POR-15) NUMBER: MPAPS P-9555 TITLE: Quality Requirements For Fuel Tanks REVISION: 1406 This document is restricted and may not be se

45、nt outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. JUNE 2014 Page 9 of 11 TABLE 1. SURFACE APPEARANCE ACCEPTANCE CRITERIA Appearance Zones: Class A defined as the glamour finish

46、area, just in front of the tank seam weld area and T-weld area (approx. 11 oclock position) to the bottom of the tank (6 oclock position). Also includes entire surface of the head/end-cap of the tank. (See section below on weld repair zone classification allowance on welds.) Class B defined as the n

47、onvisual area when the tank is mounted on the truck. Includes area from bottom of tank (6 oclock position) around the back of the tank to past the seam weld and T-weld area (11 oclock). ALUMINUM Item Criteria NON-POLISHED AL VISUAL Scratches Zone A - Not allowed to be felt by hand, or more than 25 m

48、m in length nor 1 mm wide. Zone B - Not allowed to be greater than 0.5 mm deep, 25 mm long and/or 2.5 mm wide. Abrasions Zone A - None allowed Zone B - Multiple scratches the total of which must be less than 25 mm in diameter and meet the other criterion of “Scratches” Gouges (deeper than 1 mm) Zone A - None allowed. Zone B - Total not to exceed 2 mm wide nor 25 mm in length Dents (in or out) Zone A - None allowed Zon